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  #31  
Old September 8th, 2019, 15:35
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devildog0 devildog0 is offline
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transfer case questions

Take it to the car wash and power wash it off. Certainly a good idea to clean exterior before stripping it down. Keeps unnecessary dirt out.

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2004 Suzuki DL650 VStrom/1978 Suzuki GS1000E/2003 Yamaha TW200
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  #32  
Old September 9th, 2019, 18:59
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Re: transfer case questions

Quote:
Originally Posted by devildog0 View Post
Take it to the car wash and power wash it off. Certainly a good idea to clean exterior before stripping it down. Keeps unnecessary dirt out.

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good idea but.
Good @$@**ing luck. no chance of that for me.
This is 30 years of Axle Grease,Transmission fluid, motor oil and dirt.
when the shop cleaned the block it took 6 days in the hot tank.

This stuff is not coming off with a pressure washer at any pay and spray. Trust me I have already tried.

This is Spray with simple green and a screwdriver/rag combo. to take it off.
enjoy pics.
it certainly does not do the disgusting justice...




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  #33  
Old September 9th, 2019, 19:00
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Re: transfer case questions

https://imgshare.io/image/IA7uf
https://imgshare.io/image/IAnbH
https://imgshare.io/image/IA3Pd
links to pics since it wont post them
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  #34  
Old September 9th, 2019, 19:01
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Re: transfer case questions

oh.
Also.
Bad bad bad news.
someone has been in here before. Note the black silicone in the pictures ....
Crosses fingers...
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  #35  
Old September 10th, 2019, 08:51
RCP Phx RCP Phx is offline
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Re: transfer case questions

It would be the opportune time to get a SYE installed!
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  #36  
Old September 10th, 2019, 18:19
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Re: transfer case questions

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Originally Posted by RCP Phx View Post
It would be the opportune time to get a SYE installed!
or not because hack and tap is the best way to go.
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  #37  
Old September 10th, 2019, 18:22
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Re: transfer case questions

im about 9 hours worth of scrubbing this transfer case. and we are 60%~ clean.
the fluid smells really burned. and there is barely any in there. but no metal flakes. so im hoping the shafts are good and just the chain stretched.
Not opening it until I ensure I dont spew nast onto the inside.
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  #38  
Old September 10th, 2019, 18:39
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Re: transfer case questions

anyone got a suggestion on where I can buy a new speedo gear ? the one in there is pretty chewed up
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  #39  
Old September 10th, 2019, 19:24
lawsoncl lawsoncl is offline
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Re: transfer case questions

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Originally Posted by blu3fan View Post
oh.
Also.
Bad bad bad news.
someone has been in here before. Note the black silicone in the pictures ....
Crosses fingers...


I've got a 1992 242J on the bench waiting to be rebuilt that has exact same black permatex. Google images also show a lot of pictures with black sealer. It's a junkyard pull so I can't be sure, but I suspect it's never been rebuilt and it came from the factory that way.
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  #40  
Old September 10th, 2019, 21:11
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Re: transfer case questions

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Originally Posted by lawsoncl View Post
I've got a 1992 242J on the bench waiting to be rebuilt that has exact same black permatex. Google images also show a lot of pictures with black sealer. It's a junkyard pull so I can't be sure, but I suspect it's never been rebuilt and it came from the factory that way.
interesting.
thanks for the info.
just so much over the edge I couldn't believe factory did that bad a job lol
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  #41  
Old September 10th, 2019, 21:26
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Re: transfer case questions

Wow.
I just found this.
Turns out you dont even have to remove the xfer case to take it apart.
I mean I wanted to clean mine off anyways. but still.
enjoy.
http://mallcrawlin.com/forum/showthr...n-of-the-NV242
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  #42  
Old September 11th, 2019, 08:14
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devildog0 devildog0 is offline
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transfer case questions

Eh. They're not difficult to remove and rebuilding it on a bench makes for a much more pleasant experience than doing all the work under a vehicle. Possible exception being having it on a lift.

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  #43  
Old September 11th, 2019, 10:12
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Re: transfer case questions

Honestly I feel like all the grease under the car makes me want to remove and Clean it anyways so it's a better option. But still good I know you can split the case under the car
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  #44  
Old September 11th, 2019, 14:32
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Re: transfer case questions

Quote:
Originally Posted by blu3fan View Post
anyone got a suggestion on where I can buy a new speedo gear ? the one in there is pretty chewed up
quadratec is easiest
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  #45  
Old September 11th, 2019, 14:40
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Re: transfer case questions

Quote:
Originally Posted by blu3fan View Post
im about 9 hours worth of scrubbing this transfer case. and we are 60%~ clean.
the fluid smells really burned. and there is barely any in there. but no metal flakes. so im hoping the shafts are good and just the chain stretched.
Not opening it until I ensure I dont spew nast onto the inside.
look for bluing on the gears (blue on the planetary is normal but not on the gears), that's the best indicator of overheating internally. also check the thrust washers for wear / missing. if there's no bluing and no excess movement on the planetary gears then you are probably fine but if they are blue or move a lot you may need to rebuild.

often times a lot of brass dust and such in the differential from the synchro. 50/50 on cleaning them, sometimes the cruft is holding everything together at the right off-set, and if you clean it out the synchro gets some slop and starts to chatter / skip. I do not know of any aftermarket synchros or differentials.

Good opportunity to upgrade the high-low planetary to six-pinion set. 231 sets are often on ebay. Need one to match the gear cut of your case (94-down and 95-up).
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